Modular Light Bar With Keyed Circuit Boards
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Solution Overview
Problem
The complexity of emergency vehicle light bars, with densely packed wiring and multiple connections, leads to manufacturing challenges, increased risk of errors, and reliability issues due to mechanical and electrical failures from vibration and temperature cycling.
Innovation Solution
A modular construction approach using circuit boards with keying systems to precisely mount and align light beam assemblies, reducing loose wiring and enhancing assembly efficiency, with each board featuring areas for multiple assemblies and complementary keys for registration, and a single cable for power and control signals, optionally including wireless power and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional wiring schemes with multiple individual connectors are used to accommodate customizable lighting devices, then adaptability to customer demands is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The light bar is divided into modular light assemblies, each with its own circuit board. This segmentation allows different lighting devices to be independently configured while reducing overall wiring complexity, as each module handles its own electrical connections separately.
Solution Approach 2:
A universal housing structure and mounting system is designed that can accommodate various types of lighting devices (LEDs, halogen, strobes, lasers) and configurations. The standardized interfaces and mounting mechanisms allow different light sources to be installed in the same physical platform.
2Adaptability or versatility
If densely packed wiring schemes are used to support multiple lighting devices, then adaptability to customer specifications is improved, but manufacturing time and error risk increase
Solution Approach 1:
By segmenting the electrical system into separate circuit boards for each light assembly, the patent eliminates the need for complex inter-connections between devices. Each assembly is self-contained with its own wiring, dramatically reducing assembly time and error risk while maintaining full configurability.
Solution Approach 2:
Circuit boards are pre-configured with wiring and connectors before final assembly. This preliminary preparation of electrical connections allows for rapid installation of light assemblies without requiring complex on-site wiring work.
3Adaptability or versatility
If multiple individual wire connectors are used to support various lighting configurations, then adaptability is improved, but reliability decreases due to vibration and temperature cycling
Solution Approach 1:
Each light assembly is electrically isolated on its own circuit board with dedicated connectors. This segmentation reduces the total number of connection points in the system, thereby reducing potential failure points from vibration and thermal cycling while maintaining configurability.
Solution Approach 2:
The patent employs robust connector designs and wiring harnesses that are pre-engineered to withstand vibration and temperature extremes. Stress relief features and secure mounting of electrical connections are built into the design to prevent failures before they occur.
4Adaptability or versatility
If complex wiring schemes with multiple connections are used, then adaptability to customer demands is improved, but ease of repair and servicing deteriorates
Solution Approach 1:
The modular architecture with individual circuit boards for each light assembly allows faulty components to be easily identified and replaced independently. This segmentation transforms complex wiring repair into simple module-level replacement or targeted component repair.
Solution Approach 2:
The design allows for easy replacement of individual light assemblies or circuit boards when failures occur. Rather than servicing complex interconnected wiring, entire modules can be quickly swapped out and replaced with new or refurbished units.
Data Source
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AI summary
A light bar is described that is of a modular construction based on one or more large circuit boards that are populated with light beam assemblies and then fastened to an interior space of the light bar housing. Keys that automatically align the light beam assemblies on each of the boards precisely control placement of the assemblies on the board. In turn, each of the boards is keyed to the interior of the light bar housing so that when the board is fastened to the housing the light beam assemblies are automatically registered into alignment with the lenses in the housing so that the beams from the assemblies are properly oriented. The light bar is inexpensive to fabricate and can be assembled quickly and reliably, yet it provides for a high degree of customization, which is a requirement in the emergency vehicle lighting industry.